Electrical Resistance Activation of Embedded Fe-SMA Rebars in Pre-Cracked UHPFRC Beams: Internal Temperature Evolution and Calibrated Electro-Thermal Simulation

Iron-based shape memory alloy (Fe–SMA) rebars can generate internal prestress in cement-based members after restrained thermal activation; however, the temperature actually reached by embedded rebars in cracked UHPFRC is difficult to infer from exposed bar segments. This study investigates electrical resistance activation of 4% prestrained Fe–SMA rebars embedded in pre-cracked UHPFRC beams and clarifies the activation-control problem by combining thermocouple measurements with a calibrated two-dimensional electro-thermal simulator. Twelve beams (150 × 150 × 600 mm) containing either Dramix 3D or Dramix 4D hooked steel fibers were first loaded in three-point bending to a mid-span displacement of 4 mm. The 4D series reached a 9.47% higher average pre-cracking load, confirming that fiber geometry modified the cracked state before heating. During activation, the exposed rebar segment reached 200 °C after approximately 77 s, whereas the embedded working segment reached the same target only after approximately 213 s; at that moment, the exposed segment was already close to 350 °C. The calibrated simulator reproduced the target activation time with an error of approximately 3 s and visualized the localized heat transfer from Fe–SMA to UHPFRC. The results demonstrate that activation control based only on exposed-bar temperature may cause under-activation of the embedded reinforcement, and that direct internal temperature monitoring is required for reliable Fe–SMA activation in cracked UHPFRC members.